Multi-head tufting system

ABSTRACT

A multi-needle tufting gun for use in robotic tufting includes a support and a plurality of tufting modules mounted to the support, wherein at least one tufting module is movably mounted to the support such that the at least one tufting module is selectively spaced relative to at least another tufting module mounted to the support. Each tufting module comprises a tufting needle. A spacing actuator mounted to the support selectively moves the at least one tufting module relative to another tufting module, wherein the selective relative movement is in at least one axis across a tufting plane of a sheet of backing material to be tufted. In some examples, the tufting module includes self-contained tufting cartridges. There is also disclosed a tufting frame for conveying a backing material through a tufting area.

BACKGROUND Technical Field

The present disclosure relates to tufting, and more specifically totufting needles and tufting guns including constituent components.

Description of the Related Art

The simplest tool for hand tufting is a narrow, thin walled, hollowcylindrical tube acting as a needle. One end of the needle is beveled toform a needle point and yarn is fed through the other open end. Thisneedle penetrates a backing material to create a hole. The inner edge ofthe needle, opposite the point, pulls yarn through the hole as theneedle is inserted. When the needle is withdrawn a loop tuft is formed.The needle is then rotated so the needle point is facing in thedirection of to the next insertion point. It is moved to that point andinserted to create another loop tuft. The height of the loop tuft isdetermined by how far the needle is pushed through the backing. Theweight of this tufting tool is around 50 grams.

Around 1957 Tai Ping Carpets introduced an electro-mechanical handtufting gun which was a needle and blade tufting mechanism powered by anelectric hand drill. Crank/connecting rod/slider mechanisms, powered bythe drill motor, were used to separately reciprocate the needle and theblade. The gun contained a yarn brake which, when combined with ascissor mechanism attached to the blade, enabled tufting of cut pile. Animprovement of the tufting gun used a blade containing a sharp V toreplace the scissors. Another later improvement was the addition of ahand lever driven rotating presser foot. Yet another improvement waspowering a feed roller by the motor to feed yarn into the tufting gun.Electro-mechanical hand tufting guns increase hand tufting productivityby a factor 4 to 5. A disadvantage is the weight of the tufting gun,between 2 to 3 kilograms, which makes their use physically demanding.Another disadvantage is that changing pile type and pile heights is timeconsuming and quite complex mechanical adjustments.

Electro-pneumatic hand tufting guns were mentioned in Patent ApplicationDE2815801 A1 (Hartleb), published 18 Oct. 1979, U.S. Pat. No. 4,388,881A (Price), published 21 Jun 1983 and German patent DE 2621360 C2(Verzicht), published 6 Dec. 1984. Hofmann Handtuft-Technik GmbH inGermany was producing electro-pneumatic tufting guns prior to 1983.Pneumatic tufting guns, powered by an electric motor, use a jet ofcompressed air, instead of a yarn blade, to insert yarn, through theneedle, into the backing. The needle is reciprocated by acrank/connecting rod/slider mechanism. Cut pile is produced by arotating a blade, powered by the electric motor, laterally across theface of the tufting needle to cut the yarn. Electro-pneumatic handtufting guns increase hand tufting productivity by a factor of 6 to 7times. A disadvantage is the weight of the tufting gun, between 4 to 6kilograms, which makes their use even more physically demanding thanelectro-mechanical tufting guns. Manufacturers recommend use of acounter balance to support the gun during tufting. Another disadvantageis that changing pile type and pile heights requires spare parts and istime consuming and mechanically quite complex.

Whereas tufting guns mechanized hand tufting, automation of hand tuftingwas disclosed by U.S. Pat. No. 5,503,092 (Aubourg, Pongrass, Wilson) in1996. The method and system of automated tufting has since become knownas “robot tufting.” A tufting robot consists of a computer controlledtufting gun mounted on a computer controlled co-ordinate movement systemoperating under the control of a CAM tufting system. The computercontrolled tufting gun mounted on a carriage of the movement system hasbecome known as a “tufting head.” Further improvements to tufting gunsemployed as tufting heads were in disclosed in a number of subsequentpatents. U.S. Pat. No. 5,829,372 (Aubourg, Pongrass, Wilson) disclosed arotating tufting head where the reciprocating mechanism remainedstationary. U.S. Pat. No. 7,218,987 B2 (Mile, Wilson) disclosed a methodof controlling a tufting head to selectively tuft cut pile or loop pile,known “cut/loop tufting.” U.S. Pat. No. 8,225,727 B2 (Wilson, Mile, VanWoerkom) discloses a method of controlling a tufting head to selectivelyvary the tuft pile height, known as “3D tufting.” The combination ofthis feature with U.S. Pat. No. 7,218,987 B2 is known as “3D cut/looptufting.” Tufting robots have increased the overall productivity of handtufting by a factor greater than 40 times.

BRIEF SUMMARY

There is provided a multi-needle tufting gun for use in robotic tufting,the tufting gun comprising:

-   -   a support;    -   a plurality of tufting modules mounted to the support, wherein        at least one tufting module is movably mounted to the support        such that the at least one tufting module is selectively spaced        relative to at least another tufting module mounted to the        support, and    -   wherein each tufting module comprises a tufting needle.

The tufting gun may further comprise a spacing actuator mounted to thesupport to move the at least one tufting module relative to anothertufting module.

The spacing actuator may comprise a motor and a lead screw configured toengage a corresponding drive nut on the at least one tufting module.

The lead screw may comprise a first threaded portion threaded in a firstdirection on a first side of neutral point and a second threaded portionthreaded in a second direction on a second side of the neutral point.

A pitch of the first threaded portion may be greater at a greaterdistance from the neutral point.

A pitch of the second threaded portion may be greater at a greaterdistance from the neutral point.

A pitch of the lead screw may vary along the length of the lead screw.

The tufting gun may further comprise a reciprocation actuator mounted tothe support to reciprocate the tufting needle of each tufting module.

The reciprocation actuator may comprise a linear actuator and a needleplate.

The reciprocation actuator may comprise a motor and a crank shaft.

The tufting gun may further comprise a rotation actuator mounted to thesupport to rotate the tufting needle of each tufting module.

The rotation actuator may comprise a motor and one or more worm drivesto operatively rotate each tufting needle.

The rotation actuator may comprise a linear actuator and linkages tooperatively rotate each tufting needle.

The support may further comprise a pivot to allow rotation of thetufting gun relative to a backing material.

Each tufting module may comprise a filament feed system and the tuftinggun further comprises a rotatable feed shaft having formations forengaging corresponding formations in each filament feed system.

The tufting gun may further comprise a controller and wherein eachtufting module may further comprise:

-   -   a reciprocation actuator controllable by the controller to        selectively reciprocate the tufting needle; and    -   a filament feed system controllable by the controller to        selectively feed a filament to the tufting needle.

The tufting gun may further comprise an electric motor to translate thetufting gun through space in a tufting direction, wherein the electricmotor is torque limited when a tufting needle engages a backing materialto reduce radial distorting forces by the tufting needle engaged in thebacking material.

At least one tufting module may be selectively movable relative to thesupport in an opposite direction to a tufting direction such that thetufting needle is stationary relative to the backing material to reduceradial distorting forces by the tufting needle engaged in the backingmaterial.

At least one tufting module may be movable relative to the support andresiliently biased to move in a tufting direction by a spring membersuch that a radial distorting force on the tufting needle by engagementwith a backing material causes the at least one tufting module to movein an opposite direction to the tufting direction relative to thesupport.

At least one tufting module may be movable relative to the support andfurther comprising a linear actuator configured to bias the tuftingmodule in a tufting direction when the tufting needle is not engaging abacking material and further configured to allow the tufting module tomove in an opposite direction to the tufting direction when the tuftingneedle is engaging the backing material thereby to reduce radialdistorting forces by the tufting needle engaged in the backing material.

According to a second aspect, there is provided a frame for tufting of abacking material, the frame comprising:

-   -   a tensioning system to tension the backing material at a tufting        area;    -   a feed system to convey the backing material through the tufting        area.

The tufting area may comprise a substantially planar tufting plane, andwherein the feed system may convey the backing material across thetufting plane along a first axis.

The tensioning system may tension the backing material in the tuftingplane substantially along the first axis.

The tensioning system may tension the backing material in a second axis,wherein the second axis is across the tufting plane and substantiallyperpendicular to the first axis.

The feed system may comprises at least one movable belt or track tosupport, at least in part, the backing material in the tufting area.

The feed system may comprise at least one pair of continuous tracks toengage with, and convey, the backing material along the first axis,wherein the at least one pair of continuous tracks comprises:

-   -   a first continuous track to engage a first periphery of the        backing material passing through the tufting area; and    -   a second continuous track to engage a second periphery, opposite        to the first periphery, of the backing material passing through        the tufting area.

The at least one pair of continuous tracks, may, at least in part, havea divergent section to form at least part of the tensioning system,wherein as the continuous tracks convey the backing material along thefirst axis, the divergent section may tension the backing material alongthe second axis.

The feed system may comprise at least one tenter needle track having aplurality of tenter needles for engaging the backing material.

The tensioning system may comprise a spreader to bi-directionallytension the backing material.

The backing material may be drawn from a spool of backing material.

The feed system may be configured to convey the backing material betweenthe tufting area and a non-tufting area.

The non-tufting area may comprise at least one substantially planarnon-tufting plane.

The feed system may extend through the tufting area and the non-tuftingarea and securely engage the backing material.

The feed system may comprise at least one track extending through thetufting area and the non-tufting area, the track engageable with thebacking material for indexed movement of the backing material throughthe tufting area.

The present disclosure also provides a tufting cartridge for use in atufting system, the tufting cartridge comprising: a support housing; areciprocation actuator mounted in the support housing to reciprocate atufting needle relative to the support housing; a rotation actuatormounted in the support housing to rotate the tufting needle relative tothe support housing; a filament feed system to selectively feed afilament to the tufting needle and to control tension of the filamentpassing through the tufting needle; a cartridge controller to enableselective operation of the reciprocation actuator, the rotationactuator, and the filament feed system; a communication interface toenable communication between an external computer system and thecartridge controller, wherein the cartridge controller is configured toenable selective operation of the reciprocation actuator, the rotationactuator, and the filament feed system in response to instruction fromthe external computer system.

In some examples of the tufting cartridge, the communication interfacemay comprise a wireless communication module to enable wirelesscommunication with the external computer system.

The tufting cartridge may further comprise: a control output interfaceto enable communication between the cartridge controller and at leastone external actuator, wherein the cartridge controller is configured tosend an external actuator control signal to enable selective operationof the at least one external actuator in response to instruction fromthe external computer system, and wherein the at least one externalactuator is configured to translate and/or rotate the tufting cartridge.

In some examples of the tufting cartridge, the external actuator controlsignal is associated with a specified tufting angle for the tuftingneedle relative to a backing material to be tufted. In some examples ofthe tufting cartridge, the external actuator control signal isassociated with specifying one or more distances between the tuftingcartridge and the backing material to be tufted.

In some examples, the tufting cartridge further comprises: at least onemount at the support housing, wherein operation of the at least oneexternal actuator is operative to translate and/or rotate the tuftingcartridge by the at least one mount.

In some examples of the tufting cartridge, the at least one mountincludes a pivot, or forms part of a pivot mechanism.

In some examples of the tufting cartridge, the filament feed systemincludes a pneumatic feed system comprising: an air jet nozzle togenerate a stream of compressed gas to entrain the filament to thetufting needle.

There is also provided a multi-needle tufting head for use in robotictufting, the tufting head comprising: a support; and a plurality ofindependently operable tufting cartridges mounted to the support,wherein at least one of the tufting cartridges is movably mounted to thesupport such that at least one tufting cartridge is selectively spacedrelative to at least another tufting cartridge mounted to the support,wherein each tufting cartridge is configured to perform tuftingoperations with a reciprocating needle and filament.

In some examples of the multi-needle tufting head, the plurality ofindependently operable tufting cartridges comprise a tufting cartridgedescribed in the examples above.

There is also provided a multi-needle tufting gun according to examplesdescribed above, wherein the tufting module comprise a tufting cartridgeas described in the examples above.

There is also provided a robot tufting machine system comprising: aframe for tufting of a backing material, the frame comprising: atensioning system to tension the backing material at a tufting area; afeed system to convey the backing material through the tufting areaalong an x-axis; a tufting carriage movable relative to the tufting areain the x-axis; a support supported by the tufting carriage and movablerelative to the tufting area in a y-axis that is perpendicular to thex-axis; one or more tufting cartridges mounted to the support, whereinthe at least one or more tufting cartridges are selectively movablerelative to the support in at least a z-axis that is perpendicular toboth the x-axis and the y-axis, the tufting, wherein each tuftingcartridge is configured to perform tufting operations with areciprocating needle and filament. Tufting can include at least one of:operating one or more of the tufting cartridges while maintaining thebacking material stationary in the x-axis relative to the frame with thefeed system, and moving the tufting carriage in the x-axis relative tothe frame; or operating one or more of the tufting cartridges whilemoving the backing material in the x-axis through the tufting area withthe feed system, and maintaining the tufting carriage stationaryrelative to the frame.

In some examples of the robotic tufting machine system, moving thetufting carriage during tufting includes moving the tufting carriage ina forward direction along the x-axis, and moving the backing materialduring tufting includes moving the backing material in an oppositebackward direction along the x-axis.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1A is an illustration of a multi-needle tufting gun;

FIG. 1B is an illustration of a multi-needle tufting gun;

FIG. 1C is an illustration of a multi-needle tufting gun;

FIG. 1D is an illustration of a multi-needle tufting gun;

FIG. 1E is an illustration of a multi-needle tufting gun;

FIG. 2A is a cross-section of an exemplary tufting module;

FIG. 2B is an illustration of an exemplary tufting module;

FIG. 2C is a cross-section of an exemplary tufting module;

FIG. 2D is an illustration of an exemplary tufting module;

FIG. 3A is a cross-section of an exemplary tufting module;

FIG. 3B is an illustration of an exemplary tufting module;

FIG. 3C is a cross-section of an exemplary tufting module;

FIG. 3D is an illustration of an exemplary tufting module;

FIG. 3E is a cross-section of an exemplary tufting module;

FIG. 4A is a cross-section of an exemplary tufting module;

FIG. 4B is an illustration of an exemplary tufting module;

FIG. 4C is a cross-section of an exemplary tufting module;

FIG. 4D is an illustration of an exemplary tufting module;

FIG. 5A is a cross-section of an exemplary tufting module;

FIG. 5B is an illustration of an exemplary tufting module;

FIG. 5C is a cross-section of an exemplary tufting module;

FIG. 5D is an illustration of an exemplary tufting module;

FIGS. 6A to 6F illustrate the movement of a tufting module duringtufting;

FIG. 7A is an end elevation view of a tufting frame;

FIG. 7B is a side elevation view of a tufting frame;

FIG. 7C is a perspective view of a tufting frame;

FIG. 8 shows a robot tufting system;

FIG. 9 is a side view of a tufting frame;

FIG. 10 illustrates a tufting frame engaged by multiple tufting guns;

FIG. 11 illustrates a lead screw;

FIG. 12 illustrates an example of a tufting cartridge;

FIGS. 13 a and 13 b illustrate a tufting system utilizing a plurality oftufting cartridges;

FIG. 14 illustrates tufting at a specified tufting angle; and

FIG. 15 illustrates an example of a robot tufting machine system usingtufting cartridges.

DETAILED DESCRIPTION

Tufting is a type of weaving in which a filament is inserted through abacking material by a tufting gun to form a tuft. For example, in theprocess of producing chenille fabric or carpet making, yarn is insertedthrough a backing material to form tufts. The process is however,applicable to filamentary materials other than yarn depending on theintended purpose.

Multi-Needle Gun

Typically, tufting gun output is limited to tufting rate of a singletufting needle. Areas filled with identical tufts require a tufting gunto traverse the backing material many times. The rate of tufting islimited to the speed of a single tufting needle. In the followingdisclosure, a multi-needle is a tufting gun will be described. Thistufting gun increases the rate of tufting proportionally to the numberof tufting needles. Accordingly, the productivity of a tufting robotusing a tufting head employing a multi-needle tufting gun issignificantly increased.

Multi-Needle Gun

FIGS. 1A to 1E illustrate a multi-needle tufting gun 100 for use inrobotic tufting. Tufting gun 100 comprises a support 27, a plurality oftufting modules 36, 37 and 38 mounted to support 27. At least onetufting module of modules 36, 37 and 38 is movably mounted to thesupport 27 such that the at least one tufting module is selectivelyspaced relative to at least another tufting module mounted to thesupport. Each tufting module 36, 37 and 38 comprises a tufting needle102 as illustrated in FIG. 2A.

The tufting needle 102 may be a standard tufting needle, or aneedle-blade as described in Australian provisional patent application2019904414, which is hereby incorporated. Needle-blades may be rotatingneedles or non-rotating needles.

Tufting gun 100 may further comprise a pivot 28 to allow rotation of thetufting gun relative to a backing material 29.

Each tufting module may tuft with a different yarn. This provides theability to change tufting yarn by simply selecting another tufting headwith the new yarn, as required for color changes in a design. Currentlytufting robots stop at a yarn or color change in a design and anoperator is required to change the yarn or color. Usually one operatorcan only operate tufting 1-3 robots. Using a multi-gun tufting gunenables designs to run unattended and would enable an operator to runmany more machines.

Modules

FIGS. 2 to 5 show side and end elevation sections of a tufting module36, 37, 38.

FIGS. 2A, 2B show the needle-blade in the topmost position and FIGS. 2C,2D with needle-blade in bottommost position. The housing of the tuftingmodule 39 is supported on the module guide rods 33 passing through guideholes in the housing. The feed roller drive shaft 34 passes through thedriven feed roller and the lead screw 35 passes through the drive nut 40which is fixed to the housing. The horizontal position of the tuftingmodule relative to the tufting gun housing 27 is varied by rotation ofthe lead screw. The needle support rods 32, held in the needle plateassembly 31, pass horizontally through the needle rod guide holes in theneedle-blade 8. The needle-blade itself is guided in the vertical planeby the bearing 41 with the bottom surface of the bearing 10 acting as apresser foot. On a signal from the controller, the linear actuators movethe needle plate assembly 31, the needle support rods 32, and theattached needle-blades of the tufting modules towards the backingmaterial. The needle-blades 8, attached to the needle support rods,penetrate the backing material and travel until the desired pile heightis achieved.

FIG. 3 shows sections of side and end elevation of a pneumatic tuftingmodule with nonrotating needle. FIGS. 3A, 3B show the needle-blade inthe topmost position and FIGS. 3C, 3D with needle-blade in bottommostposition. A presser foot 10 is formed by the bottom surface of thetufting module housing 39, which holds the air jet nozzle 20. Thecutting blade pinion drive shaft 42 is mounted on and moves with theneedle bar. It is hexagonal in shape, passing through and driving thepinion gear 43 of each tufting module (although it is to be appreciatedother keying means are suitable). The pinion gear is connected to a rackcutting blade 44 which has a rack gear profile and a sharpened edge thatacts as a cutting blade. When the shaft 42 is rotated, the pinion 43rotates and moves the rack cutting blade 44 in a linear horizontalmotion across the hole at the top of the needle 102 to cut the yarn. Theposition of the cutting blade relative to the needle surface is alwaysmaintained because they are mounted and travel together on the needleplate assembly.

FIG. 4 shows sections of side and end elevation of a mechanical tuftingmodule with a rotating needle. FIGS. 4A, 4B show the needle-blade in thetopmost position and FIGS. 4C, 4D with needle-blade in bottommostposition. The rotating presser foot bearing 47 is located at the bottomof the housing and its bevel gear surface 48 engages with the worm gear45. The worm gear is rotated by the hexagonal worm gear drive shaft 46which is common to all tufting modules in the tufting gun. Rotation ofthe worm gear causes the rotating presser foot to rotate which in turnrotates the tufting needle 102. The tufting needle 102 is held by theneedle guide 49 and is free to rotate. The needle guide sits on theneedle support rods 32 of the needle plate assembly 31 and transfers theneedle plate vertical movement to the tufting needle-blade.

FIG. 5 shows sections of side and end elevation of a pneumatic tuftingmodule with rotating needle. FIGS. 5A, 5B show the needle-blade in thetopmost position and FIGS. 5C, 5D with needle-blade in bottommostposition. The rotating tufting needle-blade 52 incorporates a bevel gearprofile on its external surface 48 which engages with the worm gear 45located on the worm gear drive shaft. The needle-blade 52 is held in theneedle bearing guide 51 and is free to rotate. The needle guide sits onthe needle support rods of the needle plate and transfers the needleplate vertical movement to the tufting needle-blade.

Spacing Actuator

In some embodiments, a means of adjusting the spacing of tufting modulesin multi-needle tufting guns, as disclosed in previous embodiments, isincluded. The distance between each tufting module 36, 37 and 38 isadjusted by a single rotary actuating system while maintaining equalspacing between tufting modules. This can change the stitch spacing fora design, or between designs.

Referring to FIGS. 1A to 1E, spacing between tufting needles isachievable using a spacing actuator 14. In some embodiments, spacingactuator 14 is a lead screw actuator comprising a motor 16 and a leadscrew 35 configured to engage a corresponding drive nut 40 (shown inFIG. 2A) on the at least one tufting module 36, 37, 38.

Motor 16 rotates lead screw 35 to adjust the spacing between themultiple tufting modules. Another servo motor, attached to a commonrotary actuator, rotates the actuator to rotate all the needlessimultaneously. Thus all needles are oriented correctly for the comingtufts.

The lead screw 35, shown in more detail in FIG. 11 , may comprise afirst portion 19 threaded in a first direction on a first side ofneutral point 21, and a second portion 22 threaded in a second directionon a second side of the neutral point 21. The neutral point is notthreaded. This configuration allows a tufting module located at theneutral point to remain stationary relative to support 27 and willmainly be used with an odd number of modules.

For example, in FIG. 1D, center tufting module 36, located at theneutral point 21, remains stationary while the tufting module on eitherside moves due to rotation of the lead screw 35. The drive nuts oneither side of neutral rotate in opposite directions causing tuftingmodules 37 and 38 to move away from center tufting module 36 asindicated by arrows 101.

For configuration having more than three tufting modules, the pitch ofthe first threaded portion and/or second threaded portion is greater ata greater distance from the neutral point. This ensures that tuftingmodules which are a greater distance from the neutral point move fasteras a result of lead screw rotation ensuring that module spacings remaineven.

The nut for each tufting module has a specific lead angle so as to movethe tufting module the specific amount lead to maintain equal spacing.For example, a five needle multi-needle tufting gun, shown in FIG. 1E,fixes the position of the center module and adjusts the position ofneedles to the left and to the right. The first needle to the right, R1,may have a clockwise lead of 1 mm/rotation, with the second needle, R2,a clockwise lead of 2 mm/rotation. Needles L1 and L2 have anticlockwiseleads of 1 mm and 2 mm respectively. When the lead screw actuator isrotated clockwise, R1 and R2 move away from the center needle,maintaining equal spacing between each needle. Similarly L1 and L2 moveaway from the center needle, in the opposite, maintaining equal spacingbetween each needle. The lead screw actuator may be operated manually orby an electronically controlled motor.

Needle Reciprocator

Tufting gun 100 may further comprise a reciprocation actuator mounted tosupport 27. Reciprocation actuator comprises linear actuators 30 areattached to the support 27 (also referred to as housing) connecting itto the needle plate assembly 31 to reciprocate the needle plate with itsattached needles. The actuator stator is rigidly connected to thehousing with the actuator moving core attached at the other end to theneedle plate assembly. A pair of needle support rods 32 which passthrough each tufting module to support their tufting needles are rigidlyattached to the needle plate 31. Downward movement of the linearactuators causes the needle bar to move towards the surface of thebacking material 29, simultaneously forcing synchronized penetration ofthe backing material by all the needles in the tufting modules.Reversing the motion of the linear actuators withdraws the needle platewith its connected needles to form tufts of yarn at each tufting module.

In some embodiments, the reciprocation actuator comprises a motor and acrank shaft. Each needle is connected to the crank shaft which isrotated by the motor causing the needles to reciprocate. In someembodiment, the crank shaft is configured such that the needles aresynchronized, while in other embodiments the needles are out of phase.

Needle Rotator

In some embodiments, tufting gun 100 comprises a rotation actuatormounted to the support 27 to rotate the tufting needle 102 of eachtufting module. This allows the tufting gun to change the direction oftufting without having to rotate the whole tufting gun.

Turning to FIG. 4 , a means of simultaneous needle rotation is the useof a worm gear 45 in each tufting module driven by a common rotary shaft46. The direct needle rotator in each tufting module contains a bevelgear profile which matches with the worm gear. When the worm gear isrotated in the XY plane, the needle rotator and its connected needle isrotated about the

Z axis. The rotary actuator may be operated manually or by anelectronically controlled motor.

In some embodiments, the rotation actuator comprises a linear actuatorand linkages to each needle 102 to operatively rotate each needle. Thelinear actuator drives the linkages on an axis perpendicular to theneedle axis causing each needle to rotate on its axis. For example, thelinkages may comprise a shaft having gear teeth which engagecorresponding gear teeth in the rotating presser foot.

Force Limiting

During tufting, relative movement between tufting gun 100 and backingmaterial 29 is required. XY movement systems are programmed to traversethe tufting head over tufting frame at a constant speed while thetufting needle moves in and out of the backing material. At some timeduring the tufting cycle, the tufting needle is engaged in the backingmaterial while the head is moving, applying a force to the filaments ofthe backing surrounding needle 102. The force exerted by the tuftingneedle is generated by the torque of the servo motors driving the XYmovement system. This force causes an elliptical elongation of the holein the backing material, in the direction of tufting. This results indistortion of the backing material. Minimizing distortion and stoppingbreakage of filaments necessitates the use of high tensile strengthbacking materials. Low tensile strength backing materials like cotton,as used in hand tufting, cannot withstand the rigors of current robottufting and are subject to breakage. Below are described methods forreducing this force.

In an embodiment, the electric motor electric motor used to translatethe tufting gun through space in a tufting direction, is torque limitedwhen the tufting needle engages a backing material. The limited torquereduces forces, exerted radially from the needle onto the backingmaterial.

Turning to FIG. 6 , a mechanism for reducing distorting forces on thebacking material is described. The tufting module 600, represented bytufting needle 60, is movable relative to support 27 in an oppositedirection 62 to a tufting direction 64 of tufting gun 100. The movementof tufting module 600 is electronically controlled such that whentufting needle 60 engages backing material 29, tufting module 600 movesin an opposite direction relative to support 27 such that the tuftingneedle is stationary relative to the backing material. With no movementbetween the tufting needle and backing, there is no force exerted by thetufting needle on the backing.

This can be achieved by a force control system 66 attached betweentufting module 600 and the support 27 in FIG. 6A yarn 602 is fed throughthe tufting gun 32 into the tufting needle 60. The tufting needle 60 ispositioned at backing grid space x1, y1 in preparation for a needlepenetration. It has moved from the previous tuft 68 which was insertedin the backing material 29. In FIG. 6B, the tufting needle 60 ispenetrating the backing material as the remainder of the tufting head,such as support 27, is moving in a tufting direction 64 towards the nextpenetration point x2, y2. Simultaneously the force control system 66 ismoving tufting module 600, and therefore needle 60, in the oppositedirection to the tufting head at the same speed, thereby maintaining thetufting needle at position x1, y1. The tufting needle reaches its end ofstroke in FIG. 6C while the tufting head 27 and tufting module 600continue to move in opposite directions. In FIG. 6D, the tufting needle60 withdraws 70 from the backing forming a tuft 72 while tufting head 27and force control system 66 continuing to move in opposite directions atequal speed. When the tufting needle has been fully withdrawn from thebacking material as shown in FIG. 6E, the stabilizer reverses direction74 and moves at maximum speed towards x2, y2 to meet up with a startingposition 604 on tufting head 27. When tufting head and tufting module600 have both reached x2, y2 as shown in FIG. 6F, the tufting gun andtufting needle are position to produce the next tuft.

In some embodiments, a linear actuator is configured to bias the tuftingmodule 600 in a tufting direction 64 when the tufting needle 60 is notengaging a backing material 29. This is shown in FIG. 6E, where tuftingneedle 60 is withdrawn (i.e., not engaged) from backing material 29 andthe linear actuator causes the tufting module to move 74 relative to thesupport 27. When tufting needle 60 is engaged with backing 29 (FIGS. 6Bto 6D), the linear actuator allows the tufting module 600 to move in anopposite direction 62 to the tufting direction. This can be achieved byde-energizing the linear actuator when tufting needle 60 is engagingbacking material 29.

In an embodiment, the tufting module 600 is mounted such that it ismovable, in a direction opposite 62 the tufting direction 64, relativeto the support 27. The module is resiliently biased to move in thetufting direction 64 by a spring member. When the tufting needle engagesthe backing material 29 (FIG. 6B), radial forces on the tufting needle(from the backing material) cause the tufting module 600 to move in thedirection opposite to the tufting direction (FIGS. 6B to 6D) and againstthe resilient bias of the spring member. When the tufting needle iswithdrawn (FIG. 6E) from the backing material, the spring member movesthe module in the tufting direction 64. Allowing tufting module 600 tomove relative to support 27 in a direction 62 opposite to the tuftingdirection 64 reduces the distorting forces exerted on the backingmaterial by the tufting needle.

Tufting Frame

Tufting frames are used in robot tufting applications to hold backingmaterial in a tensioned state defining a plane. The tensioned backingmaterial is presented to a tufting head which traverses over the surfaceof the plane, tufting it in a desired pattern. The size of a tufted rugis determined by the XY dimensions of the coplanar tufting frame.Accordingly, the tufting field of the tufting robot matches thedimensions of the tufting frame. For example, a 24 square meter rugrequires a tufting frame of 4 meters high and 6 meters wide with atufting robot having a matching field. The XY movement system of thetufting robot is over 5 meters in height.

Furthermore, the size and inertia of the tufting robot's XY movementsystem is the main determinant of the cost and performance of thetufting robot. The physical dimensions of the tufting frame alsodetermine the manufacturing space required for operation of the tuftingrobot. Generally tufting frames and tufting robots are verticallyoriented, necessitating factory space with high ceilings. A furtherconsequence is that attaching and detaching backing material to thetufting frame requires the use of elevating platforms or scaffolding.

A frame 700 for tufting of a backing material 29 is shown with in FIGS.7A, 7B, and 7C. Frame 700 reduces the travel requirements for a tuftinghead to tuft backing material of given dimensions. This results inreduced size and inertia of the tufting robots XY movement system andreduced vertical clearance requirements.

Frame 700 comprises a tensioning system to tension the backing material29 at a tufting area 80 and a feed system to convey the backing materialthrough the tufting area.

In this example, frame 700 holds stretched backing material 29 on pinsof needle tracks 17 on either side of the frame. The left and rightneedle tracks 17, which form part of the tensioning system, are guidedby a number of tenter rollers 11 which form part of the feed system.

The tenter rollers are located on drive shafts 12 powered by a drivemotor 13. The backing material is positioned by drive motor at any pointalong its length, as determined by a computer control system. Thebacking material is presented by the tenter frame 700 to a tufting robotin a tufting plane. The tufting plane 82 could be the vertical sectionshown in the end elevation of FIG. 7A or the top horizontal sectionshown in side elevation of FIG. 7B or 7C. The indexing of the backingmaterial along its length by the tenter frame is synchronized with theoperation of a tufting robot by the computer control system.

The tufting area 80 comprises a substantially planar tufting plane 82,and wherein feed system conveys the backing material 29 across thetufting plane along a first axis.

This embodiment holds a length of tensioned backing material in a tenterframe in multiple planes 82, 84 etc. The motion of the frame, underelectronic control, is bi-directional and intermittent (or in someembodiments continuous). The tensioned backing material is attached tothe frame along its width. The backing material may be indexed and heldstationary to present a section for tufting by a tufting robot. Thesection of backing material to be tufted may be in the vertical orhorizontal planes. After tufting the selected section of backingmaterial, the tufting frame advances the backing to the next section tobe tufted. A design may be indexed to start in the middle and tuftoutwards or simply indexed to tuft from one end to the other. A designcan be tufted by color in sections of the design or across the fulllength of the backing to more evenly distribute the weight of thetufting. The number and direction of indexes is not limited.

This embodiment of tufting frame overcomes the problems of existingtufting frames. The short dimension of a tufted rug is defined by thewidth of the frame with the long dimension defined by the length of thetenter track. For example, a tenter frame which is 5 meters wide with arectangular tenter track 2 meters high and 2 meters long can be used totuft a rug measuring 5 meters by 8 meters. Using an XY movement systemwhose height is 2, a tufting robot can tuft the design by indexing thetufting frame 4 times.

The motor 13 powering the tufting frame may be fixed onto the frame ordetachable from the frame when the tenter is not positioning the backingmaterial. The tenter frame may be mobile or fixed in position. A designmay be tufted uni-directionally where the tenter frame progresses thebacking material in sections of the design that are completely tuftedbefore indexing. Where a design is completed in this manner, the backingmaterial may be fed continuously from its source and completed sectionsof the design removed. This can provide tufted fabric whose length islimited only by the length of the source of backing material. The tentertufting frame also enables robot tufting of rugs much larger than thosecurrently available. It also enables the use of lower height tuftingrobots which are less expensive and have better tufting performance thanexisting tufting robots.

FIG. 8 shows frame 700 in operation with a robot tufting machine 800.Robot tufting machine 800 may comprise multi-needle tufting gun 100 or aconventional tufting head. Primary backing material 29 supplied from thesource 802 and fed into the spreader 804 which attaches the backingmaterial to the tenter needle track 17. The spreader 23 is set tobi-directionally tension the backing material as it is fed onto thetenter needle track. A computer control system controls the speed of thetenter drive motor 13 and synchronizes the action of the spreader as thetensioned backing material is progressively attached to the needletrack. The tenter rollers 11, driven by the drive shafts 12 progress theattachment of the backing material to the tenter frame, loading thebacking material until the desired length of material has been fullyattached. The primary backing material is then cut and the spreaderdisconnected from the tenter frame.

When the full length of primary backing material has been attached tothe tenter tufting frame, the first section of backing material to betufted is presented to the robot tufting machine 800. When the tuftingof the design on the presented section has been completed, the tuftingframe, under the control of the computer control system indexes thebacking material to the next section of the design to be tufted. Thesequence of tufting and indexing of the backing material is repeateduntil the design has been completely tufted.

Secondary backing material from the source 806 is introduced to thespreader 804 and attached to the tenter needle track 17, on top of thepreviously attached tufted primary backing. The tenter tufting frame isdriven forward in one direction until the full length of secondarybacking material has been attached and held in the tenter frame on topof and joined to the previously tufted primary backing material. Thesecondary backing material is then cut to length and disconnected fromthe spreader.

The tenter tufting frame now grips on its needle track a fabricstructure comprising a tufted primary backing material and a secondarybacking material. The computer control system indexes the fabricstructure to position it, section by section, under the adhesiveapplication system 808. The adhesive application system, under thecontrol of the computer control system lowers the applicator head topress against the fabric structure and to start the application of theadhesive. The computer control system traverses the adhesive applicatorover the surface of the fabric structure as it regulates the flow ofadhesive onto it.

When the section of the fabric structure presented to the applicatorsystem has been fully covered with adhesive the applicator head iswithdrawn from contact with the fabric structure. The tenter frame isindexed to position the next section of fabric structure under theadhesive application system for application of adhesive. This process isrepeated until the length of the complete fabric structure has beencovered in adhesive. The fabric structure covered in adhesive is left inposition in the tenter frame until the adhesive dries and sets at whichtime the fabric structure becomes a fully bonded tufted fabric.

One embodiment of the system uses a moveable tenter frame module whichcan be disconnected from the integrated system. The tenter framecontaining the wet adhesive fabric structure is removed to a separatelocation to allow the adhesive to dry and set. An empty tenter framereplaces the removed loaded frame and is connected to the other systemmodules to provide a complete system. This new system starts producingthe next design without having to wait for the adhesive to dry on theprevious design. This enables the system to be continuously engaged intufting fabric structures.

Another embodiment of the system produces bonded tufted fabric withoutincorporating a secondary backing material in the structure.

In some embodiments, the feed system conveys the backing material acrossthe tufting plane along a first axis, applying tension to the backingmaterial in the tufting plane substantially along the first axis. Thiscan be achieved, for example by source 802, also referred to a spool,applying a resistance to backing material 29 being drawn onto frame 700by rollers 11. The resistance allows tension to be created in thedirection of feed. In this case, source 802 and rollers 11 form part ofthe tensioning system. It will be appreciated that rollers 11 can engagebacking material 29 in many different ways. For example, the feed systemmay comprise at least one pair of continuous tracks, driven by rollers11, to engage with, and convey, the backing material along the firstaxis. The pair of continuous tracks comprise a first continuous track toengage a first periphery of the backing material passing through thetufting area, and a second continuous track to engage a secondperiphery, opposite to the first periphery, of the backing materialpassing through the tufting area. The tracks may comprise a plurality oftenter needles for engaging the backing material and or have a clamp toengage the backing material.

In some embodiments, as shown in side perspective view in FIG. 9 , thetensioning system tensions the backing material in a second axis 902,wherein the second axis is across the tufting plane 82 and substantiallyperpendicular to the first axis 904. For example, the at least one pairof continuous tracks 906, at least in part, has a divergent section 908to form at least part of the tensioning system. In this embodiment, thetracks 906 engage backing material 29 and convey it along a first axis904. As the backing material is conveyed along the diverging section 908of tracks, the backing material is tensioned along the second axis 902perpendicular to the first. Tensioning in the first axis can be achievedas described above, i.e., by a resisting force from spool 802 as backingmaterial 29 is drawn onto frame 700.

Alternatively, in embodiments where the at least one pair of continuoustracks comprises tenter needles for engaging the backing material,tensioning in the first axis can be achieved by increasing the spacingbetween tenter needles. This results in the backing material beingtensioned in the first axis and the second axis at the tufting area 80.

In some embodiments, the feed system is configured to convey the backingmaterial between the tufting area 80 and at least one non-tufting area.The non-tufting area may comprise at least one substantially planarnon-tufting plane 84. The feed system, which could comprise tenterneedle tracks, extends through the tufting area and the non-tufting areaand is configured to provide indexed movement of the backing materialthrough the tufting area. This allows backing material 29 to be conveyedbetween the tufting 80 and non-tufting 84 areas in an indexed fashion.Accordingly, the tufting robot is able to tuft sections of backingmaterial, which can be moved between the tufting and non-tufting areas,with a specific yarn and return to the same indexed location at a latertime to tuft with a different yarn. In some embodiments, as shown inFIG. 10 , multiple tufting areas 80 are used, each with respectivetufting guns 100.

Additional variations of the present disclosure are described below.

Tufting Cartridge

In some examples, the tufting modules are in the form of tuftingcartridges 1038 as illustrated in FIG. 12 . In some examples, thetufting cartridge 1038 is a self-contained, physically and electricallyremovable, plug in tufting module that can be used in the robot or usedin other applications where only control signals and power are neededfor operation.

Each of the tufting cartridges can be used to tuft specific yarn (e.g.,yarn type, color, etc.). In some examples, the robotic tufting systemmay include multiple tufting cartridges (as illustrated in FIG. 13 ) toenable quick and efficient color change. In some examples, this includesusing a robotic tufting system with a flatbed plotter type arrangement,where the plotting head moves the tufting cartridge 1038 to the desiredlocation at the backing material for tufting. Such a system can includemoving the tufting cartridges in an X and Y axis to the desired locationacross a sheet of the backing material. An additional Z axis can be usedto selectively displace the tufting cartridge 1038 and, respectivetufting needle 102, towards or away from the surface of the backingmaterial 29.

The plurality of tufting cartridges 1038 mounted on a support 27 of thetufting system 1100 (as illustrated in FIGS. 13 a and 13 b ) may beindependently operable. Thus at least one of the tufting cartridges ismovable mounted to the support such that at least one tufting cartridgecan be selectively spaced relative to at least another tufting cartridgemounted to the support.

Turning to FIG. 12 , the tufting cartridge 1038 includes a supporthousing 1040 to enable the tufting cartridge 1038 to self-contain andsupport various components. This includes a reciprocating actuator 1050mounted to the supporting housing to reciprocate a tufting needle 102relative to the support housing 1040. The reciprocating actuator 1050can include a linear actuator, or in other examples a motor and crankshaft to create reciprocating motion. A rotation actuator 1052 ismounted to the support housing to rotate the tufting needle relative tothe support housing 1040. The rotation actuator 1052 can include a wormdrive system 1053 to selectively rotate the tufting needle 102.

A filament feed system 1054 selectively feeds a filament 1066 (e.g.,yarn) to the tufting needle 102 and controls tension of the filament1066 passing through the tufting needle. This can include a motor drivenfeed wheel 1055 to control feeding of the filament 1066. The filament1066 can be contained in a spool 1067 inside the support housing 1040.

In some other examples, the filament feed system 1054 can include an airjet nozzle to generate a stream of compressed gas to entrain thefilament to the tufting needle 102. This can be used to drive thefilament through the hole in the backing material opened by the tuftingneedle 102. In some examples, the filament feed system includes afilament port to introduce filament to the filament feed system 1054,and a convergent and divergent jet nozzle formed symmetrically about thefilament port and configured to generate a supersonic stream ofcompressed gas to entrain the filament to a tufting needle. An exampleof a filament feed system using an air jet is described in PCTapplication no. PCT/AU2020/051262, filed 20 Nov. 2020, which is herebyincorporated by reference.

The operation of the reciprocation actuator 1050, rotation actuator1052, and filament feed system 1054 to effect tufting may be similar, orthe same, as the earlier described examples.

The tufting cartridge 1038 also includes a cartridge controller 1056 toenable and control selective operation of the reciprocating actuator1050, rotation actuator 1052, and filament feed system 1054. Thecartridge controller 1056 can include microcontroller including aprocessor and memory to execute program instructions. These programinstructions, when executed, cause the cartridge controller 1056 to sendcontrol signals to operate the reciprocation actuator 1050, rotationactuator 1052, and filament feed system 1054.

The tufting cartridge 1038 also includes a communication interface 1058to enable communication between an external computer system 1060 and thecartridge controller 1056. This communication can include the cartridgecontroller 1056 receiving instructions from the external computer system1060 for tufting operations. In turn, the cartridge controller 1056processes the instructions and outputs the control signals to thereciprocation actuator 1050 (for needle penetration), rotation actuator1052 (for needle rotation), and the filament feed system (for feedingthe filament).

In some examples, the communication interface 1058 includes a wiredconnection to the external computer system 1060. In other examples, thecommunication interface 1058 includes a wireless communication module1062 to enable the cartridge to wirelessly communicate with the externalcomputer system 1060. This may include communication via Bluetoothand/or Wi-Fi protocols. In some examples, using wireless communicationcan reduce complexities in inserting, removing and swapping the tuftingcartridges. In some preferred examples, this enables the tuftingcartridge 1038 to require electrical connection for power. In yetfurther examples, the tufting cartridges receive power through inductivecoils for power and/or charging. This can further reduce electricalconnectors and wired connections.

Further features of a tufting cartridge, according to some examples,will now be described.

In one example, the cartridge controller 1056 is configured toselectively control one or more external actuators 1066 outside of thetufting cartridge 1038. The tufting cartridge 1038 may include a controloutput interface 1064 to enable communication between the cartridgecontroller 1056 and the one or more external actuators 1066. Thisenables actuator control signals to be sent from the cartridgecontroller 1056 to operate the external actuators 1066 in response toinstructions that the cartridge controller 1056 receives from theexternal computer system 1060.

The external actuators can include actuators to translate the tuftingcartridge in the X axis and/or the Y axis (such as a flatbed plottertype of movement).

In other examples, one or more of the external actuators 1066 move thetufting cartridge 1038 in a Z-axis. This can include, for example, alinear actuator to move the tufting cartridge 1038′ a specified distancefrom the backing material 29 to be tufted. When a particular tuftingcartridge 1038′ is used, the linear actuator may move that particulartufting cartridge 1038′ in the Z-axis (as illustrated in FIG. 13 a ) sothat the reciprocating tufting needle 102 can effectively penetrate thebacking material 29. When that particular tufting cartridge 1038′ is notrequired, the linear actuator may withdraw that particular tuftingcartridge 1038′ at a specified distance away from the backing materialin the Z-axis (as illustrated in FIG. 13 b ).

In some examples, the cartridge controller 1056 is configured to controlat least 4 axes, notably the reciprocation actuator 1050, rotationactuator 1052, filament feed system 1054, and a linear actuator on theZ-axis. An advantage is that this enables the movement system associatedwith the support 27 to be a simple X and Y axis movement system. In someexamples, this simplification can aid simple design or adaptation ofexisting bed plotter type robotic systems.

In yet another example, one or more of the external actuator 1066 isconfigured to rotate the tufting cartridge 1038 in an axis (such as theX or Y axis). This can be used to enable tufting at a specified tuftingangle 1068 as illustrated in FIG. 14 . In some examples, rotation of thetufting cartridge 1038 can be in addition to translation in the Z axis(with the cartridge controller 1056 configured to control at least 5axes). By using the cartridge controller 1056 to control theseadditional degrees of freedom, this may simplify movement of othercomponents of the tufting system so that existing systems (both hardwareand software) can be used or adapted to use the tufting cartridge.

Turning back to FIG. 12 , the tufting cartridge may further include oneor more mounts 1070 at the support housing 1040, wherein operation ofthe at least one actuator 1066 is operative to translate and/or rotatethe tufting cartridge by at least one mount 1070. In some examples, themount can include apertures to receive corresponding mounting elementsto secure the tufting cartridge 1038 for movement. In some examples, themount 1070 includes a pivot or is part of a pivot mechanism to enablethe tufting cartridge 1038 to be selectively rotated by one or more ofthe external actuators 1066.

The tufting cartridge 1038 and tufting system 1100 can be used duringmanufacture of carpets. In addition, the tufting cartridge 1038 andtufting system 1100 can be used in other industries that require passingfilament through material. For example, during manufacture of certaincomposite material (such as fiber reinforced plastics), it is desirableto layer multiple layers of woven material together whereby the layersare then laminated to each other with a resin. For complex shapes orparts, difficulties can arise keeping such layers together before theresin is fully cured. Tufting can be used to join layers of materialtogether. Referring to the example of FIG. 14 , the backing material 29includes multiple layers of woven material and the filament, with thetufting loops, hold the multiple layers of woven material together. Thepresent disclosure, in enabling the tufting cartridge 1038 to form tuftsat specified angles 1068, may assist forming of layers of woven materialwhere the application includes forming the material in complex andnon-linear molds.

Bi-Directional Operation

The use of tufting cartridges can reduce the complexity of a robottufting machine system. For example, the tufting head and correspondingsupport 27 can hold multiple cartridges, whereby each cartridge withtheir respective filaments can be individually engaged for tuftingoperations. This can include situations where non rotating tuftingneedles are used.

Another example of a robot tufting machine system 1800 is illustrated inFIG. 15 . This examples includes a frame 700 similar to the framedescribed in FIG. 8 above where the frame includes a tensioning system804 to tension the backing material at a tufting area 80. A feed system802 conveys the backing material 29 through the tufting area along anx-axis. In some examples, the feed system 802 can convey the backingmaterial 29 in a forward direction along the x-axis or an oppositebackward direction along the x-axis.

The robot tufting machine system 1800 also includes a tufting head that,in conjunction with other components, provide simple X-Y movement totufting cartridges across the tufting area 80. This can include atufting carriage 1078 that is movable to the tufting area 80 along thex-axis. The tufting carriage 1078 carries a support 27 thus movement ofthe tufting carriage 1078 along the x-axis also causes movement of thesupport 27 along the x-axis.

The support 27 is movable relative to the tufting area 80 in a y-axisthat is perpendicular to the x-axis. This can include having the support27 movably mounted to the tufting carriage 1078 and with actuatorsmoving the support 27 along the carriage 1078 in the y-axis.

One or more tufting cartridges 1038 are mounted to the support 27, wherethe tufting cartridges 1038 are selectively movable relative to thesupport 27 in the z-axis. This z-axis is perpendicular to both thex-axis and the y-axis so that movement bring the tufting cartridge 1038closer or away from the tufting area 80.

When tufting operations are required, a tufting cartridge 1038 with theappropriate filament is selected and positioned closer to the backingmaterial 29 by movement along the z-axis.

The relative position of needle of the tufting cartridge 1038 to thebacking material 29 in the y-axis can be selected by movement of thesupport 27 relative to the tufting carriage 1078.

The relative movement of a reciprocating needle of a tufting cartridge1038 relative to the backing material 29 in the x-axis can be created inmultiple ways. Firstly, by operating one or more of the tuftingcartridges while moving the tufting carriage 1078 in the x-axis relativeto the frame 700. This can coincide with maintaining the backingmaterial 29 stationary in the x-axis relative to the frame 700 with thefeed system 802.

Secondly, operating one or more of the tufting cartridges 1038 whilemoving the backing material 29 in the x-axis through the tufting area 80with the feed system 802, and maintaining the tufting carriage 1078stationary relative to the frame 700.

It is to be appreciated relative movement in the x-axis (or movementwith a vector component in the x-axis) can be created with a combinationof movement of the backing material with the feed system 802 and movingthe tufting carriage 1078 relative to the frame 700.

In some examples, in particular where the tufting needles arenon-rotating, it is desirable to maintain relative movement of thetufting needle to the backing material in the same direction along thex-axis. Thus in one example, the system is configured to move thetufting carriage 1078 in a forward direction along the x-axis duringtufting. When effecting relative movement by moving the backing material29 with the feed system 802, this includes moving the backing materialin an opposite backward direction along the x-axis during tufting.

It will be appreciated by persons skilled in the art that numerousvariations and/or modifications may be made to the above-describedembodiments, without departing from the broad general scope of thepresent disclosure. The present embodiments are, therefore, to beconsidered in all respects as illustrative and not restrictive.

The various embodiments described above can be combined to providefurther embodiments. All of the U.S. and foreign patents and applicationpublications, and non-patent publications referred to in thisspecification and/or listed in the Application Data Sheet areincorporated herein by reference, in their entirety. Aspects of theembodiments can be modified, if necessary to employ concepts of thevarious patents, applications and publications to provide yet furtherembodiments.

These and other changes can be made to the embodiments in light of theabove-detailed description. In general, in the following claims, theterms used should not be construed to limit the claims to the specificembodiments disclosed in the specification and the claims, but should beconstrued to include all possible embodiments along with the full scopeof equivalents to which such claims are entitled.

1. A multi-needle tufting gun for use in robotic tufting, the tuftinggun comprising: a movable tufting head comprising a support; a pluralityof tufting modules mounted to the support, wherein at least one tuftingmodule is movably mounted to the support such that the at least onetufting module is selectively spaced relative to at least anothertufting module mounted to the support, and wherein each tufting modulecomprises a tufting needle; a spacing actuator mounted to the support toselectively move the at least one tufting module relative to anothertufting module, wherein the selective relative movement is in at leastone axis across a tufting plane of a sheet of backing material to betufted.
 2. The tufting gun of claim 1 wherein the at least one axisincludes a first axis and a second axis perpendicular to the first axis,wherein both the first axis and the second axis are across the tuftingplane.
 3. The tufting gun of claim 1 wherein the spacing actuatorcomprises a motor and a lead screw configured to engage a correspondingdrive nut on the at least one tufting module.
 4. The tufting gun ofclaim 3 wherein the lead screw comprises a first threaded portionthreaded in a first direction on a first side of a neutral point and asecond threaded portion threaded in a second direction on a second sideof the neutral point.
 5. The tufting gun of claim 4 wherein a pitch ofthe first threaded portion is greater at a greater distance from theneutral point.
 6. The tufting gun of claim 4 wherein a pitch of thesecond threaded portion is greater at a greater distance from theneutral point.
 7. The tufting gun of claim 3 wherein a pitch of the leadscrew varies along the length of the lead screw.
 8. The tufting gun ofclaim 1 further comprising a reciprocation actuator mounted to thesupport to reciprocate the tufting needle of each tufting module. 9-10.(canceled)
 11. The tufting gun of claim 1 further comprising a rotationactuator mounted to the support to rotate the tufting needle of eachtufting module. 12-13. (canceled)
 14. The tufting gun of claim 1 whereinthe support further comprises a pivot to allow rotation of the tuftinggun relative to a backing material. 15-16. (canceled)
 17. The tuftinggun of claim 1 further comprising an electric motor to translate thetufting gun through space in a tufting direction, wherein the electricmotor is torque limited when a tufting needle engages a backing materialto reduce radial distorting forces by the tufting needle engaged in thebacking material.
 18. The tufting gun of claim 1 wherein at least onetufting module is selectively movable relative to the support in anopposite direction to a tufting direction such that the tufting needleis stationary relative to the backing material to reduce radialdistorting forces by the tufting needle engaged in the backing material.19. The tufting gun of claim 1 wherein at least one tufting module ismovable relative to the support and resiliently biased to move in atufting direction by a spring member such that a radial distorting forceon the tufting needle by engagement with a backing material causes theat least one tufting module to move in an opposite direction to thetufting direction relative to the support.
 20. The tufting gun of claim1 wherein at least one tufting module is movable relative to the supportand further comprising a linear actuator configured to bias the tuftingmodule in a tufting direction when the tufting needle is not engaging abacking material and further configured to allow the tufting module tomove in an opposite direction to the tufting direction when the tuftingneedle is engaging the backing material thereby to reduce radialdistorting forces by the tufting needle engaged in the backing material.21-34. (canceled)
 35. A tufting cartridge for use in a tufting systemhaving multiple tufting cartridges, the tufting cartridge comprising: asupport housing movable by at least one external actuator of the tuftingsystem, wherein the at least one external actuator is separate from thetufting cartridge; a reciprocation actuator mounted in the supporthousing to reciprocate a tufting needle relative to the support housing;a rotation actuator mounted in the support housing to rotate the tuftingneedle relative to the support housing; a filament feed system toselectively feed a filament to the tufting needle and to control tensionof the filament passing through the tufting needle; a cartridgecontroller to enable selective operation of the reciprocation actuator,the rotation actuator, and the filament feed system; a communicationinterface to enable communication between an external computer systemand the cartridge controller; and a control output interface to enablecommunication between the cartridge controller and the at least oneexternal actuator, wherein the cartridge controller is configured toenable selective operation of the reciprocation actuator, the rotationactuator, and the filament feed system, in response to instruction fromthe external computer system, wherein the cartridge controller isconfigured to send an external actuator control signal to enableselective operation of the at least one external actuator in response toinstruction from the external computer system, and wherein the at leastone external actuator is configured to independently translate thetufting cartridge in an x axis and/or y axis across a tufting plane of asheet of backing material to be tufted.
 36. The tufting cartridgeaccording to claim 35 wherein the communication interface comprises awireless communication module to enable wireless communication with theexternal computer system.
 37. (canceled)
 38. The tufting cartridgeaccording to claim 35 wherein the external actuator control signal isassociated with a specified tufting angle for the tufting needlerelative to the backing material to be tufted.
 39. The tufting cartridgeaccording to claim 35 wherein the external actuator control signal isassociated with specifying one or more distances between the tuftingcartridge and the backing material to be tufted. 40-41. (canceled) 42.The tufting cartridge according to claim 35 wherein the filament feedsystem includes a pneumatic feed system comprising: an air jet nozzle togenerate a stream of compressed gas to entrain the filament to thetufting needle.
 43. A multi-needle tufting head for use in robotictufting, the tufting head comprising: a support that is movable relativeto an x axis and/or y axis across a tufting plane of a sheet of backingmaterial to be tufted; a plurality of independently operable tuftingcartridges mounted to the support, wherein at least one of the tuftingcartridges is movably mounted to the support such that at least onetufting cartridge is selectively spaced relative to at least anothertufting cartridge mounted to the support, wherein each tufting cartridgeis configured to perform tufting operations with a reciprocating needleand filament; and one or more external actuators configured to translateat least one of the tufting cartridges, relative to another tuftingcartridge, in the x axis and/or y axis across the tufting plane of thesheet of backing material to be tufted. 44-47. (canceled)